ONDENSING UNIT AI ONDITIONING INSTALLATION & SEVIE EFEENE Important Safety Instructions The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner s and installer s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage. HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. ONLY individuals meeting the requirements of an Entry Level Technician as specified by the Air onditioning and efrigeration Institute (AI) may use this information. Attempting to install or repair this unit without such background may result in product damage, personal injury, or death. Shipping Inspection Always keep the unit upright; laying the unit on its side or top may cause equipment damage. Shipping damage, and subsequent investigation is the responsibility of the carrier. Verify the model number, specifications, electrical characteristics, and accessories are correct prior to installation. The distributor or manufacturer will not accept claims from dealers for transportation damage or installation of incorrectly shipped units. odes & egulations This product is designed and manufactured to comply with national codes. Installation in accordance with such codes and/ or prevailing local codes/regulations is the responsibility of the installer. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations. The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. Should you have any questions please contact the local office of the EPA. If replacing a condensing unit or air handler, the system must be manufacturer approved and Air onditioning and efrigeration Institute (AI) matched. NOTE: Installation of unmatched systems is strongly discouraged. Operating the unit in a structure that is not complete (either as Goodman Manufacturing ompany, L.P. 2005-2006 2550 North Loop West, Suite 400, Houston, TX 77092 www.goodmanmfg.com -or- www.amana-hac.com P/N: IO-258D Date: October 2006 part of new construction or renovation) will void the warranty. Installation learances Special consideration must be given to location of the condensing unit(s) in regard to structures, obstructions, other units, and any/all other factors that may interfere with air circulation. Where possible, the top of the unit should be completely unobstructed; however, if vertical conditions require placement beneath an obstruction there should be a minimum of 60 inches between the top of the unit and the obstruction(s). The specified dimensions meet requirements for air circulation only. onsult all appropriate regulatory codes prior to determining final clearances. Another important consideration in selecting a location for the unit(s) is the angle to obstructions. Either side adjacent the valves can be placed toward the structure provided the side away from the structure maintains minimum service clearance. orner installations are strongly discouraged. A A NOT EOMMENDED B B B B Minimum Airflow learance Model Type A B esidential 10" 10" 18" 20" Light ommercial 12" 12" 18" 24" This unit can be located at ground floor level or on flat roofs. At ground floor level, the unit must be on a solid, level foundation that will not shift or settle. To reduce the possibility of sound transmission, the foundation slab should not be in contact with or be an integral part of the building foundation. Ensure the foundation is sufficient to support the unit. A concrete slab raised above ground level provides a suitable base.
ooftop Installations If it is necessary to install this unit on a roof structure, ensure the roof structure can support the weight and that proper consideration is given to the weather-tight integrity of the roof. Since the unit can vibrate during operation, sound vibration transmission should be considered when installing the unit. Vibration absorbing pads or springs can be installed between the condensing unit legs or frame and the roof mounting assembly to reduce noise vibration. Safe efrigerant Handling While these items will not cover every conceivable situation, they should serve as a useful guide. To avoid possible injury, explosion or death, practice safe handling of refrigerants. efrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space.to avoid possible difficulty in breathing or death: Never purge refrigerant into an enclosed room or space. By law, all refrigerants must be reclaimed. If an indoor leak is suspected, throughly ventilate the area before beginning work. Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact and wear gloves and goggles. If liquid refrigerant does contact your skin or eyes, seek medical help immediately. Always follow EPA regulations. Never burn refrigerant, as poisonous gas will be produced. To avoid possible explosion: Never apply flame or steam to a refrigerant cylinder. If you must heat a cylinder for faster charging, partially immerse it in warm water. Never fill a cylinder more than 80% full of liquid refrigerant. Never add anything other than -22 to an -22 cylinder or -410A to an -410A cylinder. The service equipment used must be listed or certified for the type of refrigerant used. Store cylinders in a cool, dry place. Never use a cylinder as a platform or a roller. efrigerant Lines AUTION The compressor POE oil for -410A units is extremely susceptible to moisture absorption and could cause compressor failure. Do not leave system open to atmosphere any longer than necessary for installation. Use only refrigerant grade (dehydrated and sealed) copper tubing to connect the condensing unit with the indoor evaporator. After cutting the tubing, install plugs to keep refrigerant tubing clean and dry prior to and during installation. Tubing should always be cut square keeping ends round and free from burrs. lean the tubing to prevent contamination. Do NOT let refrigerant lines come in direct contact with plumbing, ductwork, floor joists, wall studs, floors, and walls. When running refrigerant lines through a foundation or wall, openings should allow for sound and vibration absorbing material to be placed or installed between tubing and foundation. Any gap between foundation or wall and refrigerant lines should be filled with a pliable silicon-based caulk, TV or a vibration damping material. Avoid suspending refrigerant tubing from joists and studs with rigid wire or straps that would come in contact with the tubing. Use an insulated or suspension type hanger. Keep both lines separate and always insulate the suction line. These sizes are suitable for line lengths of 74 feet or less. If a run of more than fifty feet is required, refer to emote ooling Service Manual, or TP-106 Long Line Set Application -22, or TP-107 Long Line Set Application -410A or contact your distributor for assistance. EFIGEANT LINE LENGTH (Ft) ond 0-24 25-49 50-74*** Unit Line Diameter (In. OD) Tons Suct Liq Suct Liq Suct Liq 1 1/2 5/8 1/4 3/4 3/8 3/4 3/8 2 5/8 1/4 3/4 3/8 3/4 3/8 2 1/2 5/8 1/4 3/4* 3/8 7/8 3/8 3 3/4 3/8 3/4** 3/8 7/8** 3/8 3 1/2 3/4 3/8 7/8** 3/8 1 1/8 3/8 4 7/8 3/8 1 1/8 3/8 1 1/8 3/8 5 7/8 3/8 1 1/8 3/8 1 1/8 3/8 * 7/8" required for full ratings ** 1 1/8" required for full ratings *** Lines greater than 74 feet in length or vertical elevation changes more than 50 feet refer to the emote ooling Service Manual or contact your distributor for assistance. To avoid possible explosion, use only returnable (not disposable) service cylinders when removing refrigerant from a system. Ensure the cylinder is free of damage which could lead to a leak or explosion. Ensure the hydrostatic test date does not exceed 5 years. Ensure the pressure rating meets or exceeds 400 lbs. When in doubt, do not use cylinder. 2
Liquid Line Suction Line Mounting the evaporator coil above the condensing unit will require an inverted loop in the suction line adjacent or near the connection to the evaporator. The top of the loop must be slightly higher than the top of the coil. Mounting the condensing unit above the evaporator coil will require oil traps at equal intervals along the suction line. Install 1 oil trap for a height difference of 15 25 feet between indoor and outdoor units. Install 2 oil traps for a difference of 26-50 feet, 3 for 51-100 feet, and 4 for 101-150 feet. 2. Sweep the refrigerant line with nitrogen or inert gas during brazing to prevent the formation of copper-oxide in- 3 side the refrigerant lines. The POE oils used in -410A applications will clean any copper-oxide present from the inside of the refrigerant lines and spread it throughout the system. This may cause a blockage or failure of the metering device. 3. After brazing, quench the joints with water or a wet cloth to prevent overheating of the service valve. 4. Ensure the filter drier paint finish is intact after brazing. If the paint of the steel filter drier has been burned or chipped, repaint or treat with a rust preventative. This is especially important on suction line filter driers which are continually wet when the unit is operating. NOTE: Be careful not to kink or dent refrigerant lines. Kinked or dented lines will cause poor performance or compressor damage. Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing. Insulation is necessary to prevent condensation from forming and dropping from the suction line. Armflex (or satisfactory equivalent) with 3/8 min. wall thickness is recommended. In severe conditions (hot, high humidity areas) 1/2 insulation may be required. Insulation must be installed in a manner which protects tubing from damage and contamination. Where possible, drain as much residual compressor oil from existing systems, lines, and traps; pay close attention to low areas where oil may collect. NOTE: If changing refrigerant types, ensure the indoor coil and metering device is compatible with the type of refrigerant being used; otherwise, the indoor coil must be replaced. Burying efrigerant Lines If burying refrigerant lines can not be avoided, use the following checklist. 1. Insulate liquid and suction lines separately. 2. Enclose all underground portions of the refrigerant lines in waterproof material (conduit or pipe) sealing the ends where tubing enters/exits the enclosure. 3. If the lines must pass under or through a concrete slab, ensure lines are adequately protected and sealed. efrigerant Line onnections IMPOTANT: To avoid overheating the service valve, TXV valve, or filter drier while brazing, wrap the component with a wet rag, or use a thermal heat trap compound as recommended by the compound manufacturer. Use a brazing alloy of 2% minimum silver content. Do not use flux. 1. The ends of the refrigerant lines must be cut square, deburred, cleaned, and be round and free from nicks or dents. Any other condition increases the chance of a refrigerant leak. NOTE: Before brazing, verify indoor piston size by checking the piston kit chart packaged with indoor unit. Leak Testing (Nitrogen or Nitrogen-Traced) To avoid the risk of fire or explosion, never use oxygen, high pressure air or flammable gases for leak testing of a refrigeration system. To avoid possible explosion, the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve. The pressure relief valve must be set to open at no more than 150 psig. Pressure test the system using dry nitrogen and soapy water to locate leaks. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure then apply the detector to suspect areas. If leaks are found, repair them. After repair, repeat the pressure test. If no leaks exist, proceed to system evacuation. System Evacuation ondensing unit liquid and suction valves are closed to contain the charge within the unit. The unit is shipped with the valve stems closed and caps installed. Do not open valves until the system is evacuated. EFIGEANT UNDE PESSUE! Failure to follow proper procedures may cause property damage, personal injury or death. 1. onnect the vacuum pump with 250 micron capability to the service valves.
2. Evacuate the system to 250 microns or less using suction and liquid service valves. Using both valves is necessary as some compressors create a mechanical seal separating the sides of the system. 3. lose pump valve and hold vacuum for 10 minutes. Typically pressure will rise during this period. VAUUM IN MIONS 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 LEAK(S) PESENT ONDENSIBLES O SMALL LEAK PESENT NO LEAKS NO ONDENSIBLES 0 1 2 3 4 5 6 7 8 9 10 MINUTES If the pressure rises to 1000 microns or less and remains steady the system is considered leak-free; proceed to startup. If pressure rises above 1000 microns but holds steady below 2000 microns, moisture and/or noncondensibles may be present or the system may have a small leak. eturn to step 2: If the same result is encountered check for leaks as previously indicated and repair as necessary then repeat evacuation. If pressure rises above 2000 microns, a leak is present. heck for leaks as previously indicated and repair as necessary then repeat evacuation. Electrical onnections HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death due to electric shock. Wiring must conform with NE or E and all local codes. Undersized wires could cause poor equipment performance, equipment damage or fire. NOTIE Units with reciprocating compressors and non-bleed TXV s require a Hard Start Kit. The condensing unit rating plate lists pertinent electrical data necessary for proper electrical service and overcurrent protection. Wires should be sized to limit voltage drop to 2% (max.) from the main breaker or fuse panel to the condensing unit. onsult the NE, E, and all local codes to determine the correct wire gauge and length. Local codes often require a disconnect switch located near the unit; do not install the switch on the unit. efer to the installation instructions supplied with the indoor furnace/air handler for specific wiring connections and indoor unit configuration. Likewise, consult the instructions packaged with the thermostat for mounting and location information. Overcurrent Protection The following overcurrent protection devices are approved for use. Time delay fuses HA type circuit breakers These devices have sufficient time delay to permit the motorcompressor to start and accelerate its load. Three Phase ompressor otation AUTION Use care when handling scroll compressors. Dome temperatures could be hot. Three phase scrolls are power phase dependent and can compress in more than one direction. Verify proper rotation for three phase compressors by ensuring the suction pressure drops and discharge pressure rises when the compressor is energized. NOTE: When operated in reverse, a three phase scroll compressors is noisier and its current draw substantially reduced compared to marked values. To correct, disconnect power and switch any two leads at the unit contactor and re-observe. High Voltage onnections oute power supply and ground wires through the high voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover. Low Voltage onnections ondensing unit control wiring requires 24 Volt minimum, 25VA service from the indoor transformer. Low voltage wiring for twostage units depends on the thermostat used and the number of control wires between the indoor unit and the condensing unit. oute control wires through the low voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover. To avoid the risk of fire or equipment damage, use copper conductors. 4
Y G W1 Thermostat Single-Stage Heating with (Single-Stage ooling AUTION Use refrigerant certified to AI standards. Used refrigerant may cause compressor damage, and will void the warranty. Most portable machines cannot clean used refrigerant to meet AI standards. O Y B/ G W1 DEHUM TWIN FUNAE O AI HANDLE NOTIE Violation of EPA regulations may result in fines or other penalties. Y EMOTE Single-Stage Thermostat with Two Low Voltage Wires to emote NOTE: For two-stage condensing units, refer to the Installation Instructions supplied with the variable speed indoor units for field wiring connections. O YLO/YI Y/Y2 YLO/YI Y/Y2 Y/Y2 YL0/Y1 G W2 W1 B/ G W1 W2 Thermostat Two-Stage Heating with (Two-Stage ooling DEHUM TWIN OD UNIT Two-Stage Thermostat with Three Low Voltage Wires to emote FUNAE O AI HANDLE System Start Up Adequate refrigerant charge for a matching evaporator and 15 feet lineset is supplied with the condensing unit. NOTE: If lineset exceeds 15 feet in length, refrigerant should be added at.6 ounces per foot of liquid line. Open each valve only until the top of the stem is 1/8 from the retainer. To avoid loss of refrigerant, do not apply pressure to the retainer. 1. Break vacuum by fully opening liquid and suction base valves. 2. Set thermostat to call for cooling. heck indoor and outdoor fan operation and allow system to stabilize for 10 minutes for fixed orifices and 20 minutes for expansion valves. harge Verification EFIGEANT UNDE PESSUE! Do not overcharge system with refrigerant. Do not operate unit in a vacuum or at negative pressure. Failure to follow proper procedures may cause property damage, personal injury or death. 5 AUTION Operating the compressor with the suction valve closed will void the warranty and cause serious compressor damage. Final harge Adjustment The outdoor temperature must be 60 F or higher. Set the room thermostat to OOL, fan switch to AUTO, and set the temperature control well below room temperature. After system has stabilized per startup instructions, check subcooling and superheat as detailed in the following section. Fixed Orifice AUTION To prevent personal injury, carefully connect and disconnect manifold gauge hoses. Escaping liquid refrigerant can cause burns. Do not vent refrigerant into the atmosphere. ecover all refrigerant during system repair and before final unit disposal. 1. Purge gauge lines. onnect service gauge manifold to base-valve service ports. un system at least 10 minutes to allow pressure to stabilize. 2. Temporarily install thermometer on suction (large) line near suction line service valve with adequate contact and insulate for best possible reading. 3. efer to the superheat table provided for proper system superheat. Add charge to lower superheat or recover charge to raise superheat. Ambient ondenser Inlet Temp. ( F Drybulb) SYSTEM SUPEHEAT eturn Air Temperature ( F Drybulb) 65 70 75 80 85 115 3 100 5 5 95 5 5 5 90 7 12 18 85 5 10 17 20 80 5 12 21 26 75 5 10 17 25 29 70 5 14 20 28 32 65 13 19 26 32 35 60 17 25 30 33 37 4. Disconnect manifold set, installation is complete. Superheat Formula = Suct. Line Temp. - Sat. Suct. Temp.
SATUATED SUTION PESSUE TEMPEATUE HAT SUTION PESSUE SATUATED SUTION TEMPEATUE ºF PSIG -22-410A 50 26 1 52 28 3 54 29 4 56 31 6 58 32 7 60 34 8 62 35 10 64 37 11 66 38 13 68 40 14 70 41 15 72 42 16 74 44 17 76 45 19 78 46 20 80 48 21 Expansion Valve System Single Speed Application 1. Purge gauge lines. onnect service gauge manifold to base-valve service ports. un system at least 10 minutes to allow pressure to stabilize. 2. Temporarily install thermometer on liquid (small) line near liquid line service valve with adequate contact and insulate for best possible reading. 3. heck subcooling and superheat. Systems with TXV application should have a subcooling of 7 ± 2 ºF and superheat of 7 to 9 ºF. a. If subcooling and superheat are low, adjust TXV to 7 to 9 ºF superheat, then check subcooling. NOTE: To adjust superheat, turn the valve stem clockwise to increase and counter clockwise to decrease. b. If subcooling is low and superheat is high, add charge to raise subcooling to 7 ± 2ºF then check superheat. c. If subcooling and superheat are high, adjust TXV valve to 7 to 9 ºF superheat, then check subcooling. d. If subcooling is high and superheat is low, adjust TXV valve to 7 to 9 ºF superheat and remove charge to lower the subcooling to 7 ± 2ºF. NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge. 4. Disconnect manifold set, installation is complete. Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp. NOTIE Units with reciprocating compressors and non-bleed TXV s require a Hard Start Kit. 6 SATUATED LIQUID PESSUE TEMPEATUE HAT LIQUID PESSUE SATUATED LIQUID TEMPEATUE ºF PSIG -22-410A 200 101 70 210 105 73 220 108 76 225 110 78 235 113 80 245 116 83 255 119 85 265 121 88 275 124 90 285 127 92 295 130 95 305 133 97 325 137 101 355 144 108 375 148 112 405 155 118 Two Speed Application un the remote on low stage cooling for 10 minutes until refrigerant pressures stabilize. Follow the guidelines and methods below to check unit operation and ensure that the refrigerant charge is within limits. harge the unit on low stage. 1. Purge gauge lines. onnect service gauge manifold to base-valve service ports. 2. Temporarily install thermometer on liquid (small) line near liquid line service valve with adequate contact and insulate for best possible reading. 3. heck subcooling and superheat. Systems with TXV application should have a subcooling of 5 to 7 ºF and superheat of 7 to 9 ºF. a. If subcooling and superheat are low, adjust TXV to 7 to 9 ºF superheat, then check subcooling. NOTE: To adjust superheat, turn the valve stem clockwise to increase and counter clockwise to decrease. b. If subcooling is low and superheat is high, add charge to raise subcooling to 5 to 7 ºF then check superheat. c. If subcooling and superheat are high, adjust TXV valve to 7 to 9 ºF superheat, then check subcooling. d. If subcooling is high and superheat is low, adjust TXV valve to 7 to 9 ºF superheat and remove charge to lower the subcooling to 5 to 7 ºF. NOTE: Do NOT adjust the charge based on suction pressure unless there is a gross undercharge. 4. Disconnect manifold set, installation is complete. Subcooling Formula = Sat. Liquid Temp. - Liquid Line Temp.
Troubleshooting Information omplaint No ooling Unsatisfactory ooling System Operating Pressures POSSIBLE AUSE DOTS IN ANALYSIS GUIDE INDIATE "POSSIBLE AUSE" SYMPTOM System will not start ompressor will not start - fan runs ompressor and ondenser Fan will not start Evaporator fan will not start ondenser fan will not start ompressor runs - goes off on overload ompressor cycles on overload System runs continuously - little cooling Too cool and then too warm Not cool enough on warm days For detailed service information refer to the emote ondensing Unit Service manual. ertain areas to cool others to warm ompressor is noisy Low suction pressure Low head pressure High suction pressure High head pressure Test Method emedy Power Failure Test Voltage Blown Fuse Impact Fuse Size & Type Loose onnection Inspect onnection - Tighten Shorted or Broken Wires Test ircuits with Ohmmeter Open Overload Test ontinuity of Overloads Faulty Thermostat Test ontinuity of Thermostat and Wiring Faulty Transformer heck ontrol ircuit with Voltmeter Shorted or Open apacitor Test apacitor Internal ompressor Overload Open Test ontinuity of Overload Shorted or Grounded ompressor Test Motor Windings ompressor Stuck Use Test ord Faulty ompressor ontactor Test ontinuity of oil and ontacts Faulty Fan elay Test ontinuity of oil and ontacts Open ontrol ircuit Test ontrol ircuit with Voltmeter Low Voltage Test Voltage Faulty Evaporator Fan Motor epair or eplace Shorted or Grounded Fan Motor Test Motor Windings Improper ooling Anticipator heck esistance of Anticipator Shortage or efrigerant Test For Leaks, Add efrigerant estricted Liquid Line eplace estricted Part Undersized Liquid Line eplace Line Undersized Suction Line eplace Line Not Enough Air across Indoor oil Speed Blower, heck Duct Static Pressure Too Much Air across Indoor oil educe Blower Speed Overcharge of efrigerant ecover Part of harge Noncondensibles ecover harge, Evacuate, echarge ecirculation of ondensing Air emove Obstruction to Air Flow Infiltration of Outdoor Air heck Windows, Doors, Vent Fans, Etc. Improperly Located Thermostat elocate Thermostat Air Flow Unbalanced eadjust Air Volume Dampers System Undersized efigure ooling Load Broken Internal Parts eplace ompressor Broken Valves Test ompressor Efficiency Inefficient ompressor Test ompressor Efficiency High Pressure ontrol Open eset and Test ontrol Unbalanced Power, 3PH Test Voltage Wrong Type Expansion Valve eplace Valve Expansion Valve estricted eplace Valve Oversized Expansion Valve eplace Valve Undersized Expansion Valve eplace Valve Expansion Valve Bulb Loose Tighten Bulb Bracket Inoperative Expansion Valve heck Valve Operation Loose Hold-down Bolts Tighten Bolts 7